Systems and Methods Providing a Computerized Eyewear Device to Aid in Welding

ABSTRACT

Systems and methods to aid a welder or welding student. A system may provide a real-world arc welding system or a virtual reality arc welding system along with a computerized eyewear device having a head-up display (HUD). The computerized eyewear device may be worn by a user under a conventional welding helmet as eye glasses are worn and may wirelessly communicate with a welding power source of a real-world arc welding system or a programmable processor-based subsystem of a virtual reality arc welding system.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/105,758, filed Dec. 13, 2013, entitled “SYSTEMS AND METHODS PROVIDINGA COMPUTERIZED EYEWEAR DEVICE TO AID IN WELDING,” which claims priorityto and the benefit of U.S. provisional patent application Ser. No.61/827,248 filed on May 24, 2013. The entireties of the aforementionedapplications are incorporated herein by reference. Published U.S. PatentApplication (US 2013/0044042) having application Ser. No. 13/212,686 andfiled on Aug. 18, 2013 is incorporated by reference herein in itsentirety. Published U.S. Patent Application (US 2010/0062405) havingapplication Ser. No. 12/501,257 and filed on Jul. 10, 2009 isincorporated by reference herein in its entirety.

TECHNICAL FIELD

Certain embodiments of the present invention relate to welding. Moreparticularly, certain embodiments of the present invention relate tosystems and methods providing visualization and communicationcapabilities to a welder using a welding system via a computerizedeyewear device.

BACKGROUND

Providing information to a welding student in real time during a weldingprocess (whether a real-world welding process or a simulated weldingprocess) is important to aid the welding student in the learningprocess. Similarly, providing information to an expert welder in realtime during a real-world welding process can aid the expert welder inthe welding process. Furthermore, providing the ability for a weldingstudent or an expert welder to easily communicate with (e.g., providecommands to) a welding system (real or simulated) can allow for a moreefficient and user-friendly welding experience. Today, a welding helmetmay be provided with simple light indicators representative of weldinginformation which don't require a welder to be able to focus sharply onthe light indicators, since the light indicators may be within one inchof the welder's eye. Simply being able to see that the color of a lightindicator is red or green or yellow, for example, is provided. Thus,there is an ongoing need to improve how a welder or welding studentinteracts with a welding system and how information is provided andviewed in real time.

Further limitations and disadvantages of conventional, traditional, andproposed approaches will become apparent to one of skill in the art,through comparison of such systems and methods with embodiments of thepresent invention as set forth in the remainder of the presentapplication with reference to the drawings.

SUMMARY

In one embodiment, a system is provided. The system includes a weldingpower source of an arc welding system and a computerized eyewear devicehaving a head-up display (HUD). The computerized eyewear device isconfigured to be worn by a user as eye glasses are worn, while the useralso wears a protective welding helmet. The computerized eyewear deviceis further configured to wirelessly communicate with the welding powersource of the arc welding system. The computerized eyewear device mayreceive information from the welding power source and display theinformation on the HUD. Furthermore, the user may provide commands tothe welding power source via the computerized eyewear device (e.g., viavoice activation). The welding power source and the computerized eyeweardevice may be cooperatively configured to provide one or more ofaugmented indicators indicative of a user's welding technique andsequencer functionality indicative of a next weld to be made on the HUD,for example.

In another embodiment, a system is provided. The system includes aprogrammable processor-based subsystem of a virtual reality weldingsimulation system and a computerized eyewear device having a head-updisplay (HUD). The computerized eyewear device is configured to be wornby a user as eye glasses are worn, while the user also wears aprotective welding helmet. The computerized eyewear device is furtherconfigured to wirelessly communicate with the programmableprocessor-based subsystem of the virtual reality welding simulationsystem. The computerized eyewear device may receive information from theprogrammable processor-based subsystem and display the information onthe HUD. Furthermore, the user may provide commands to the programmableprocessor-based subsystem via the computerized eyewear device (e.g., viavoice activation). The programmable processor-based subsystem and thecomputerized eyewear device may be cooperatively configured to provideone or more of virtual reality images associated with a virtual realitywelding process and virtual cues and indicators associated with avirtual reality welding process on the HUD, for example.

In accordance with an embodiment, the computerized eyewear deviceincludes a frame configured to be worn on the head of a user, the frameincluding a bridge configured to be supported on the nose of the user, abrow portion coupled to and extending away from the bridge to a firstend remote therefrom and configured to be positioned over a first sideof a brow of the user, and a first arm having a first end coupled to thefirst end of the brow portion and extending to a free end, the first armbeing configured to be positioned over a first temple of the user withthe free end disposed near a first ear of the user, wherein the bridgeis adjustable for selective positioning of the brow portion relative toan eye of the user. The computerized eyewear device also includes atransparent display (the HUD) which may be affixed to the frame and maybe movable with respect to the frame through rotation about a first axisthat extends parallel to the first brow portion. The computerizedeyewear device also includes a housing containing control andcommunication circuitry affixed to the frame. As an example, thecomputerized eyewear device may be a Google Glass™ device configured foroperation with an arc welding system or a virtual reality arc weldingsimulation system.

Details of illustrated embodiments of the present invention will be morefully understood from the following description and drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. I illustrates a diagram of an exemplary embodiment of an arcwelding system and a computerized eyewear device configured tocommunicate with the arc welding system;

FIG. 2 illustrates a diagram of an exemplary embodiment of thecomputerized eyewear device of FIG. 1; and

FIG. 3 illustrates a diagram of an exemplary embodiment of a virtualreality welding system and a computerized eyewear device configured tocommunicate with the virtual reality welding system.

DETAILED DESCRIPTION

The following are definitions of exemplary terms that may be used withinthe disclosure. Both singular and plural forms of all terms fall withineach meaning:

“Software” or “computer program” as used herein includes, but is notlimited to, one or more computer readable and/or executable instructionsthat cause a computer or other electronic device to perform functions,actions, and/or behave in a desired manner. The instructions may beembodied in various forms such as routines, algorithms, modules orprograms including separate applications or code from dynamically linkedlibraries. Software may also be implemented in various forms such as astand-alone program, a function call, a servlet, an applet, anapplication, instructions stored in a memory, part of an operatingsystem or other type of executable instructions. It will be appreciatedby one of ordinary skill in the art that the form of software isdependent on, for example, requirements of a desired application, theenvironment it runs on, and/or the desires of a designer/programmer orthe like.

Computer or “processing element” or “computerized device” as used hereinincludes, but is not limited to, any programmed or programmableelectronic device that can store, retrieve, and process data,“Non-transitory computer-readable media” include, but are not limitedto, a CD-ROM, a removable flash memory card, a hard disk drive, amagnetic tape, and a floppy disk.

“Computer memory”, as used herein, refers to a storage device configuredto store digital data or information which can be retrieved by acomputer or processing element.

“Controller”, as used herein, refers to the logic circuitry and/orprocessing elements and associated software or program involved incontrolling a device, system, or portion of a system.

The terms “signal”, “data”, and “information” may be usedinterchangeably herein and may be in digital or analog form.

The term “welding parameter” is used broadly herein and may refer tocharacteristics of a portion of a welding output current waveform (e.g.,amplitude, pulse width or duration, slope, electrode polarity), awelding process (e.g., a short arc welding process or a pulse weldingprocess), wire feed speed, a modulation frequency, a welding travelspeed, or some other parameter associated with real-world welding orsimulated welding.

The term “head up display”, as used herein, refers to a transparentdisplay that presents information (e.g., high quality images) withoutrequiring a user to look away from their usual viewpoints.

In one embodiment, an arc welding system is provided. The arc weldingsystem includes a welding power source and a computerized eyewear devicehaving a head-up display (HUD) and control and communication circuitry(CCC) operatively connected to the HUD, The computerized eyewear deviceis configured to be worn by a user as eye glasses are worn, while alsowearing a protective welding helmet, and wirelessly communicate with thewelding power source. The control and communication circuitry isconfigured to wirelessly receive information from the welding powersource and display the information on the HUD.

In accordance with an embodiment, the computerized eyewear deviceincludes a microphone operatively connected to the control andcommunication circuitry. The microphone and the control andcommunication circuitry are configured to receive voice-activated usercommand information and wirelessly transmit the voice-activated usercommand information to the welding power source. In accordance with anembodiment, the computerized eyewear device includes a cameraoperatively connected to the control and communication circuitry. Thecamera and the control and communication circuitry are configured tocapture one or more of still pictures and moving video. In accordancewith an embodiment, the control and communication circuitry isconfigured to access the internet through a wireless access point.

In accordance with an embodiment, the computerized eyewear deviceincludes a frame configured to be worn on the head of a user and atleast one housing affixed to the frame containing one or more of thecontrol and communication circuitry, the microphone, and the camera. TheHUD is also affixed to the frame and is movable with respect to theframe through rotation about a first axis that extends parallel to afirst brow portion. Optionally, the computerized eyewear device mayinclude at least one prescription optical lens held in place by theframe.

In accordance with an embodiment, the frame includes a bridge configuredto be supported on the nose of the user, a brow portion coupled to andextending away from the bridge to a first end remote therefrom andconfigured to be positioned over a first side of a brow of the user, anda first arm having a first end coupled to the first end of the browportion and extending to a free end. The first arm is configured to bepositioned over a first temple of the user with the free end disposednear a first ear of the user. In accordance with an embodiment, thebridge is adjustable for selective positioning of the brow portionrelative to an eye of the user.

FIG. 1 illustrates a diagram of an exemplary embodiment of an arcwelding system 100 and a computerized eyewear device 150 configured tocommunicate with the arc welding system 100. The arc welding system 100includes a wire feeder 110, a welding gun or tool 120, a shielding gassupply 130, and a welding power source 140. The wire feeder 110, thewelding gun 120, the shielding gas supply 130, and the power source 140are operatively connected to allow a welder to create an electric arcbetween a welding wire and a workpiece W to create a weld as is wellknown in the art.

In accordance with an embodiment, the welding power source 140 includesa switching power supply (not shown), a waveform generator (not shown),a controller (not shown), a voltage feedback circuit (not shown), acurrent feedback circuit (not shown), and a wireless communicationcircuit 145. The wire feeder 110 feeds the consumable wire weldingelectrode E toward the workpiece W through the welding gun (weldingtool) 120 at a selected wire feed speed (WFS). The wire feeder 110, theconsumable welding electrode E, and the workpiece W are not part of thewelding power source 140 but may be operatively connected to the weldingpower source 140 via a welding output cable.

The computerized eyewear device 150 is configured to be worn by a useras eye glasses are worn, while also wearing a conventional protectivewelding helmet. The protective welding helmet may be a conventionalwelding helmet that does not have to be modified in any way toaccommodate the computerized eyewear device 150. Furthermore, thecomputerized eyewear device 150 is configured to wirelessly communicatewith the welding power source 140 via the wireless communication circuit145 of the welding power source 140. The wireless communication circuit145 may include a processor, computer memory, a transmitter, a receiver,and an antenna, in accordance with an embodiment.

Referring now to FIG. 1 and FIG. 2, where FIG. 2 illustrates a diagramof an exemplary embodiment of the computerized eyewear device 150 ofFIG. 1, the computerized eyewear device 150 includes a frame 151configured to be worn on the head of a user. The frame 151 includes abridge 152 configured to be supported on the nose of the user and a browportion 153 coupled to and extending away from the bridge 152 to a firstand second ends remote therefrom and configured to be positioned overthe brows of the user.

The frame also includes a first arm 154 having a first end coupled tothe first end of the brow portion 153 and extending to a free end, thefirst arm being configured to be positioned over a first temple of theuser with the free end disposed near a first ear of the user. The frame151 also includes a second arm 155 having a first end coupled to thesecond end of the brow portion 153 and extending to a free end, thesecond arm being configured to be positioned over a second temple of theuser with the free end disposed near a second ear of the user. Thebridge 152 may be adjustable for selective positioning of the browportion 153 relative to the eyes of the user, in accordance with anembodiment.

The computerized eyewear device 150 includes a transparent display(e.g., a HUD) 156 affixed to the frame 151. The HUD 156 may be movablewith respect to the frame 151 through rotation about a first axis thatextends parallel to the brow portion 153, in accordance with anembodiment, and may be configured to display text, graphics, and images.The computerized eyewear device 150 also includes control andcommunication circuitry (e.g., a computer) 157 enclosed in a housing 162and affixed to the frame 151. The control and communication circuitry157 may include a processor and memory, for example. The memory may becoupled to the processor and store software that can be accessed andexecuted by the processor. The processor may be a microprocessor or adigital signal processor, for example. As an option, the computerizedeyewear device 150 may include a camera 158. The HUD 156 and the controland communication circuitry 157 (and, optionally, the camera 158) areoperatively connected to provide the functionality described herein. Inaccordance with an embodiment, the camera 158 is configured to capturestill pictures and moving video. In this way, a user may record thewelding scenario as viewed by the user from inside the welding helmet.

In accordance with an embodiment, the control and communicationcircuitry 157 provides two-way communication with the wirelesscommunication circuit 145 of the welding power source 140. Informationmay be provided from the welding power source 140 to the computerizedeyewear device 150 and displayed on the HUD 156. Furthermore, inaccordance with an embodiment, the control and communication circuitry157 is configured to accept voice-activated commands from a user andtransmit the commands to the welding power source 140. Communicationbetween the welding power source 140 and the computerized eyewear device150 may be accomplished by way of, for example, Bluetooth® radiotechnology, communication protocols described in IEEE 802.11 (includingany IEEE 802.11 revisions), cellular technology (such as GSM, CDMA,UMTS, EVDO, WiMax, or LTE), or ZigBee® technology, among otherpossibilities. In accordance with an embodiment, the computerizedeyewear device may also include at least one optical lens 163 thatmatches a user's corrective visual prescription. In accordance with afurther embodiment, the computerized eyewear device may be modular andattachable to normal prescription eye glasses.

Furthermore, in accordance with an embodiment, the welding power source140 may be accessible by the computerized eyewear device 150 via theInternet. For example, the control and communication circuitry 157 maybe configured to access the Internet through a wireless hot spot (e.g.,a smart phone or a wireless router) and access the welding power source140 therethrough. Alternatively, the welding power source 140 may beconfigured to access the Internet and provide information obtained fromthe Internet to the computerized eyewear device 150.

Information that may be displayed on the HUD 156 during a real-worldwelding scenario that may be useful to a welder may be in the form oftext, an image, or a graphic. Such information may include, for example,the arc welding process, a welding tool travel angle, a welding tooltravel speed, a tip-to-work distance, a wire feed speed, a weldingpolarity, an output voltage level, an output current level, an arclength, a dime spacing, a whip time, a puddle time, a width of weave, aweave spacing, a tolerance window, a number score, and welding sequencesteps. Other information may be displayed as well, in accordance withother embodiments. For example, in an augmented mode, instructionalindicators that are used in a virtual reality training environment maybe superimposed over an actual weld using the HUD 156. In this manner, awelding student who trained on a virtual reality welding system cantransition to a real welding scenario and have the same instructionalindicators provided via the HUD. Visual cues or indicators may bedisplayed to the welder on the HUD of the computerized eyewear device toindicate to the welder if a particular parameter (e.g., a welding tooltravel angle) is within an acceptable range or not. Such visual cues orindicators may aid in training by helping an inexperienced welder orwelding student to improve his welding technique.

The acquisition of some of the information may rely on the welding toolbeing spatially tracked (e.g., travel angle, travel speed, tip-to-workdistance). In accordance with an embodiment, the welding tool mayinclude an accelerometer device that is operatively connected to thewelding power source to provide spatial position or movementinformation. Other methods of tracking the welding tool are possible aswell, such as magnetic tracking techniques, for example.

In accordance with an embodiment, the computerized eyewear device 150includes a microphone 159 for receiving voice-activated commands from auser. The voice-activated commands, as initiated by a welder, that maybe accommodated by the computerized eyewear device 150 in communicationwith the welding power source 140 may include, for example, commands tochange a welding parameter such as a wire feed speed, a weldingpolarity, and a welding output current level. Other types of commandsmay be possible as well, in accordance with other embodiments.

In accordance with an embodiment, the computerized eyewear device 150and/or the welding power source 140 may be programmed with one or morewelding software applications configured to accommodate use of thecomputerized eyewear device 150 with the arc welding system 100. Forexample, an embodiment of one welding software application may provide a“good weld” recognition capability. Similar to a facial recognitioncapability, the “good weld” recognition capability may use the camera158 to acquire an image of a weld created by the user, analyze theimage, and provide feedback to the user on the HUD 156 as to the overallexternal quality of the weld. For example, the text “poor weld”, “fairweld”, or “good weld” may be displayed to the user. The user may have totake off his welding helmet or lift a visor on the welding helmet toacquire an image of the weld, The welding software application mayreside in the computerized eyewear device 150, the welding power source140, or a combination of both, in accordance with various embodiments.

As another example, an embodiment of a welding software application mayprovide a welding sequencing capability. When welding a part or assemblywith many welds, it is not desirable for a welder to miss a weld. Awelding software application may step a welder through the multiplewelds for the part. For example, as a welder finishes a current weld ona part or assembly requiring multiple welds, the welder may give a voicecommand of “next weld”. As a result, the welding software applicationmay display to the welder on the HUD 156 an image or graphic (e.g., a 3Drepresentation of the part) providing the location of the next weld tobe performed. The type of weld and other information associated with theweld may also be displayed. In accordance with an embodiment where thecomputerized eyewear device 150 is being spatially tracked, as discussedlater herein, the welding software application may display a graphic onthe HUD such that graphic indicator is overlaid onto the assembly at thenext location to be

Ii welded. Other types of welding software applications that operatewith the computerized eyewear device are possible as well, in accordancewith other embodiments.

In one embodiment, a virtual reality welding system is provided. Thevirtual reality welding system includes a programmable processor-basedsubsystem and a computerized eyewear device having a head-up display(HUD) and control and communication circuitry (CCC) operativelyconnected to the HUD. The computerized eyewear device is configured tobe worn by a user as eye glasses are worn, and to wirelessly communicatewith the programmable processor-based subsystem. The control andcommunication circuitry is configured to wirelessly receive informationfrom the programmable processor-based subsystem and display theinformation on the HUD.

In accordance with an embodiment, the computerized eyewear devicefurther includes a microphone operatively connected to the control andcommunication circuitry and configured to receive voice-activated usercommand information and wirelessly transmit the voice-activated usercommand information to the programmable processor-based subsystem.Alternatively, or in addition, the computerized eyewear device mayinclude a touch-sensitive user interface operatively connected to thecontrol and communication circuitry and configured to allow a user toselect command information and wirelessly transmit the commandinformation to the programmable processor-based subsystem.

In accordance with an embodiment, the computerized eyewear deviceincludes a camera operatively connected to the control and communicationcircuitry. The camera and the control and communication circuitry areconfigured to capture one or more of still pictures and moving video. Inaccordance with an embodiment, the control and communication circuitryis configured to access the internet through a wireless access point.

In accordance with an embodiment, the computerized eyewear deviceincludes a frame configured to be worn on the head of a user and atleast one housing affixed to the frame containing one or more of thecontrol and communication circuitry, the microphone, and the camera. TheHUD is also affixed to the frame and is movable with respect to theframe through rotation about a first axis that extends parallel to afirst brow portion. Optionally, the computerized eyewear device mayinclude at least one prescription optical lens held in place by theframe.

In accordance with an embodiment, the frame includes a bridge configuredto be supported on the nose of the user, a brow portion coupled to andextending away from the bridge to a first end remote therefrom andconfigured to be positioned over a first side of a brow of the user, anda first arm having a first end coupled to the first end of the browportion and extending to a free end. The first arm is configured to bepositioned over a first temple of the user with the free end disposednear a first ear of the user. In accordance with an embodiment, thebridge is adjustable for selective positioning of the brow portionrelative to an eye of the user.

In accordance with an embodiment, the computerized eyewear deviceincludes at least one motion sensing device operatively connected to thecontrol and communication circuitry and configured to provide spatialinformation to the programmable processor-based subsystem as a usermoves his head.

FIG. 3 illustrates a diagram of an exemplary embodiment of a virtualreality arc welding system 300 and a computerized eyewear device 150configured to communicate with the virtual reality welding system 300.The virtual reality arc welding (VRAW) system includes a programmableprocessor-based subsystem, a spatial tracker operatively connected tothe programmable processor-based subsystem, at least one mock weldingtool capable of being spatially tracked by the spatial tracker, and atleast one display device operatively connected to the programmableprocessor-based subsystem. In accordance with an embodiment, thecomputerized eyewear device 150 may also be spatially tracked by thespatial tracker. The system is capable of simulating, in a virtualreality space, a weld puddle having real-time molten metal fluidity andheat dissipation characteristics. The system is also capable ofdisplaying the simulated weld puddle on the display device in real-time.

The system 300 includes a programmable processor-based subsystem (PPS)310. The system 300 further includes a spatial tracker (ST) 320operatively connected to the PPS 310. The system 300 also includes aphysical welding user interface (WUI) 330 operatively connected to thePPS 310 as well as the computerized eyewear device 150 in operativewireless communication with the PPS 310 via a wireless communicationcircuit 145 of the PPS 310, The system 300 further includes an observerdisplay device (ODD) 340 operatively connected to the PPS 310. Thesystem 300 also includes at least one mock welding tool (MWT) 350operatively connected to the ST 320 and the PPS 310. The system 300further includes a table/stand (T/S) 360 and at least one welding coupon(WC) 370 capable of being attached to the T/S 360. In accordance with analternative embodiment of the present invention, a mock gas bottle isprovided (not shown) simulating a source of shielding gas and having anadjustable flow regulator.

In accordance with an embodiment, the computerized eyewear device 150 isconfigured as previously described herein. However, in this embodiment,the control and communication circuitry 157 provides two-waycommunication with the wireless communication circuit 145 of the PPS310. Information may be provided from the PPS 310 to the computerizedeyewear device 150 and displayed on the HUD 156, Furthermore, inaccordance with an embodiment, the control and communication circuitry157 is configured to accept voice-activated commands from a user andtransmit the commands to the PPS 310. Communication between the PPS 310and the computerized eyewear device 150 may be accomplished by way of,for example, Bluetooth® radio technology, communication protocolsdescribed in IEEE 802.11 (including any IEEE 802.11 revisions), cellulartechnology (such as GSM, CDMA, UMTS, EVDO, WiMax, or LTE), or ZigBee®technology, among other possibilities.

Furthermore, in accordance with an embodiment, the PPS 310 may beaccessible by the computerized eyewear device 150 via the Internet. Forexample, the control and communication circuitry 157 may be configuredto access the Internet through a wireless hot spot (e.g., a smart phoneor a wireless router) and access the PPS 310 therethrough.Alternatively, the PPS 310 may be configured to access the Internet andprovide information obtained from the Internet to the computerizedeyewear device 150.

As before, the user may wear a conventional welding helmet over thecomputerized eyewear device 150. However, since the welding scenario isa simulated welding scenario, the conventional welding helmet may befitted with a transparent lens instead of a protective lens thatprotects against the light and other radiation emitted by a real arc. Assuch, the user may see through the transparent lens to view the weldingcoupon 370 and the mock welding tool 350, for example.

In accordance with an embodiment, the computerized eyewear device 150 isconfigured with an accelerometer device 160 that is operativelyconnected to the control and communication circuitry 157. Spatialinformation provided by the accelerometer device as the user moves hishead is communicated to the PPS 110 and then to the spatial tracker 320.In this manner, the spatial relationship between the surroundingenvironment and what the user is seeing through the HUD 156 of thecomputerized eyewear device 150 may be correlated. As the user proceedswith the virtual welding process using the system 300, anythingdisplayed on the HUD 156 (e.g., a virtual weld puddle) will appearoverlaid onto, for example, the welding coupon 370 as the user views thewelding coupon through the transparent lens of the conventional weldinghelmet. In accordance with other embodiments, other motion sensingdevices besides that of an accelerometer device may be used. Acalibration procedure may be initially performed to correlate the viewof the user through the HUD to the surrounding environment, inaccordance with an embodiment.

The real-time molten metal fluidity and heat dissipation characteristicsof the simulated weld puddle provide real-time visual feedback to a userof the mock welding tool when displayed (e.g., on the HUD of thecomputerized eyewear device 150 as tracked by the spatial tracker 320),allowing the user to adjust or maintain a welding technique in real-timein response to the real-time visual feedback (i.e., helps the user learnto weld correctly). When the computerized eyewear device 150 is beingspatially tracked, the weld puddle will appear at a correct locationwith respect to the welding coupon as viewed through the HUD.

The displayed weld puddle is representative of a weld puddle that wouldbe formed in the real-world based on the user's welding technique andthe selected welding process and parameters. By viewing a puddle (e.g.,shape, color, slag, size, stacked dimes), a user can modify histechnique to make a good weld and determine the type of welding beingdone. The shape of the puddle is responsive to the movement of the gunor stick.

The term “real-time”, as used herein with respect to a virtual realityor simulated environment, means perceiving and experiencing in time in avirtual or simulated environment in the same way that a user wouldperceive and experience in a real-world welding scenario. Furthermore,the weld puddle is responsive to the effects of the physical environmentincluding gravity, allowing a user to realistically practice welding invarious positions including overhead welding and various pipe weldingangles (e.g., 1G, 2G, 5G, 6G).

Information that may be useful to a welding student to display on theHUD 156 during a virtual or simulated welding scenario may be in theform of text, an image, or a graphic. Such information may include, forexample, the arc welding process, a welding tool travel angle, a weldingtool travel speed, a tip-to-work distance, a set wire feed speed, a setwelding polarity, a simulated output voltage level, a set output currentlevel, a simulated arc length, a dime spacing, a whip time, a puddletime, a width of weave, a weave spacing, a tolerance window, a numberscore, and welding sequence steps. Other information may be displayed aswell, in accordance with other embodiments.

In accordance with an embodiment, the computerized eyewear device 150includes a microphone 159 that is operatively connected to the controland communication circuitry 157 for receiving voice-activated commandsfrom a user. The voice-activated commands, as initiated by a welder,that may be accommodated by the computerized eyewear device 150 incommunication with the PPS 310 may include, for example, commands tochange a welding parameter such as a simulated wire feed speed, asimulated welding polarity, and a simulated welding output currentlevel. Other types of commands may be possible as well, in accordancewith other embodiments.

In accordance with an embodiment, the computerized eyewear device 150and/or the PPS 310 may be programmed with one or more welding trainingsoftware applications configured to accommodate use of the computerizedeyewear device 150 with the virtual reality arc welding system 300. Forexample, an embodiment of one welding software application may provide a“good weld” recognition capability. Similar to a facial recognitioncapability, the “good weld” recognition capability may use an image of asimulated weld created by the user, analyze the image, and providefeedback to the user on the HUD 156 as to the overall external qualityof the weld. For example, the text “poor weld”, “fair weld”, or “goodweld” may be displayed to the user. The welding software application mayreside in the computerized eyewear device 150, the PPS 310, or acombination of both, in accordance with various embodiments.

As another example, an embodiment of a welding software application mayprovide a welding sequencing capability. As a welder finishes a currentsimulated weld on a welding coupon requiring multiple welds, the weldermay give a voice command of “next weld”. As a result, the weldingsoftware application may display to the welder on the HUD 156 an imageor graphic providing the location of the next weld to be performed. Thetype of weld and other information associated with the weld may also bedisplayed. In accordance with an embodiment where the computerizedeyewear device 150 is being spatially tracked, as discussed herein, thewelding software application may display a graphic on the HUD such thatthe graphic is overlaid onto the welding coupon at the next location tobe welded. Other types of welding software applications that operatewith the computerized eyewear device are possible as well, in accordancewith other embodiments.

The computerized eyewear device 150 may be configured to be used withother welding simulation systems in accordance with other embodiments.For example, welding simulations performed on a personal computer (PC)or a tablet computer may be communicatively and functionally integratedwith the computerized eyewear device 150 to aid a welding student inlearning how to weld. In some simulated and/or virtual weldingenvironments, a welding student may not wear a welding helmet of anykind. Instead, the computerized eyewear device may be the only head gearworn. One optional embodiment of the computerized eyewear device mayprovide a touch-sensitive user interface (TSUI) 161 which the weldingstudent can use instead of or in addition to voice-activated commands.Such a TSUI would be accessible to the welding student when not wearinga welding helmet, for example. In accordance with an embodiment, theTSUI 161 is operatively connected to the control and communicationcircuitry 157.

In summary, systems and methods to aid a welder or welding student areprovided. A system may include a real-world arc welding system or avirtual reality arc welding system along with a computerized eyeweardevice having a head-up display (HUD). The computerized eyewear devicemay be worn by a user under a conventional welding helmet as eye glassesare worn and may wirelessly communicate with a welding power source of areal-world arc welding system or a programmable processor-basedsubsystem of a virtual reality arc welding system.

In appended claims, the terms “including” and “having” are used as theplain language equivalents of the term “comprising”; the term “in which”is equivalent to “wherein.” Moreover, in appended claims, the terms“first,” “second,” “third,” “upper,” “lower,” “bottom,” “top,” etc. areused merely as labels, and are not intended to impose numerical orpositional requirements on their objects. Further, the limitations ofthe appended claims are not written in means-plus-function format andare not intended to be interpreted based on 35 U.S.C. §112, sixthparagraph, unless and until such claim limitations expressly use thephrase “means for” followed by a statement of function void of furtherstructure. As used herein, an element or step recited in the singularand proceeded with the word “a” or “an” should be understood as notexcluding plural of said elements or steps, unless such exclusion isexplicitly stated. Furthermore, references to “one embodiment” of thepresent invention are not intended to be interpreted as excluding theexistence of additional embodiments that also incorporate the recitedfeatures. Moreover, unless explicitly stated to the contrary,embodiments “comprising,” “including,” or “having” an element or aplurality of elements having a particular property may includeadditional such elements not having that property. Moreover, certainembodiments may be shown as having like or similar elements, however,this is merely for illustration purposes, and such embodiments need notnecessarily have the same elements unless specified in the claims.

As used herein, the terms “may” and “may be” indicate a possibility ofan occurrence within a set of circumstances; a possession of a specifiedproperty, characteristic or function; and/or qualify another verb byexpressing one or more of an ability, capability, or possibilityassociated with the qualified verb. Accordingly, usage of “may” and “maybe” indicates that a modified term is apparently appropriate, capable,or suitable for an indicated capacity, function, or usage, while takinginto account that in some circumstances the modified term may sometimesnot be appropriate, capable, or suitable. For example, in somecircumstances an event or capacity can be expected, while in othercircumstances the event or capacity cannot occur—this distinction iscaptured by the terms “may” and “may be.”

This written description uses examples to disclose the invention,including the best mode, and also to enable one of ordinary skill in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The scope of theinvention is defined by the claims, and may include other examples thatoccur to one of ordinary skill in the art. Such other examples areintended to be within the scope of the claims if they have structuralelements that do not differentiate from the literal language of theclaims, or if they include equivalent structural elements withinsubstantial differences from the literal language of the claims.

While the invention of the present application has been described withreference to certain embodiments, it will be understood by those skilledin the art that various changes may be made and equivalents may besubstituted without departing from the scope of the invention. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the invention without departing from itsscope. Therefore, it is intended that the invention not be limited tothe particular embodiments disclosed, but that the invention willinclude all embodiments falling within the scope of the appended claims.

What is claimed is:
 1. A virtual reality welding system, comprising: aprogrammable processor-based subsystem; and a computerized eyeweardevice having a head-up display (HUD) and control and communicationcircuitry (CCC) operatively connected to the HUD, wherein thecomputerized eyewear device is configured to: be worn by a user as eyeglasses are worn; and wirelessly communicate with the programmableprocessor-based subsystem.
 2. The system of claim 1, wherein the controland communication circuitry is configured to wirelessly receiveinformation from the programmable processor-based subsystem and displaythe information on the HUD.
 3. The system of claim 1, wherein thecomputerized eyewear device further includes a microphone operativelyconnected to the control and communication circuitry and configured toreceive voice-activated user command information and wirelessly transmitthe voice-activated user command information to the programmableprocessor-based subsystem.
 4. The system of claim 1, wherein thecomputerized eyewear device further includes a camera operativelyconnected to the control and communication circuitry and configured tocapture one or more of still pictures and moving video.
 5. The system ofclaim 1, wherein the control and communication circuitry is configuredto access the internet through a wireless access point.
 6. The system ofclaim 1, wherein the computerized eyewear device further includes aframe configured to be worn on the head of a user.
 7. The system ofclaim 6, wherein the computerized eyewear device further includes atleast one housing affixed to the frame containing one or more of thecontrol and communication circuitry, a microphone, a motion sensingdevice, a touch-sensitive user interface, and a camera.
 8. The system ofclaim 6, wherein the HUD is affixed to the frame and is movable withrespect to the frame through rotation about a first axis that extendsparallel to a brow portion of the frame.
 9. The system of claim 6,wherein the computerized eyewear device further includes at least oneprescription optical lens held in place by the frame.
 10. The system ofclaim 6, wherein the frame includes a bridge configured to be supportedon the nose of the user, a brow portion coupled to and extending awayfrom the bridge to a first end remote therefrom and configured to bepositioned over a first side of a brow of the user, and a first armhaving a first end coupled to the first end of the brow portion andextending to a free end, the first arm being configured to be positionedover a first temple of the user with the free end disposed near a firstear of the user.
 11. The system of claim 10, wherein the bridge isadjustable for selective positioning of the brow portion relative to aneye of the user.
 12. The system of claim 1, wherein the computerizedeyewear device further includes at least one motion sensing deviceoperatively connected to the control and communication circuitry andconfigured to provide spatial information to the programmableprocessor-based subsystem as a user moves his head.
 13. The system ofclaim 1, wherein the computerized eyewear device further includes atouch-sensitive user interface operatively connected to the control andcommunication circuitry and configured to allow a user to select commandinformation and wirelessly transmit the command information to theprogrammable processor-based subsystem.
 14. The system of claim 1,wherein the programmable processor-based subsystem and the computerizedeyewear device are cooperatively configured to provide one or more ofvirtual reality images associated with a virtual reality welding processand virtual cues and indicators associated with a virtual realitywelding process on the HUD.
 15. A welding simulator, comprising: aprogrammable processor-based subsystem configured to simulate a weldingoperation; and a computerized eyewear device configured to be worn by auser during the simulated welding operation, the computerized eyeweardevice having a wireless communication interface, a head-up display, aprocessor, and a memory, wherein the processor is configured to executecomputer-executable instructions stored on the memory to configure thecomputerized eyewear device to: communicate with the programmableprocessor-based subsystem via the wireless communication interface; anddisplay information related to the simulated welding operation on thehead-up display.
 16. The welding simulator of claim 15, wherein thecomputerized eyewear device further includes a microphone, and whereinthe computerized eyewear device is further configured to voice commandsfrom the user via the microphone and communicate information related tothe voice commands to the programmable processor-based subsystem via thewireless communication interface.
 17. The welding simulator of claim 15,wherein the computerized eyewear device further includes a camera, andwherein the computerized eyewear device is further configured to captureimages with the camera during the simulated welding operation.
 18. Thewelding simulator of claim 15, wherein the computerized eyewear devicefurther includes at least one motion sensing device, and whereincomputerized eyewear device is further configured to spatially track amotion of the user's head with the at least one motion sensing deviceand communicate information related to the motion to the programmableprocessor-based subsystem via the wireless communication interface. 19.The welding simulator of claim 15, wherein the programmableprocessor-based subsystem executes computer instructions to cause theprogrammable processor-based subsystem to generate a virtual weld duringthe simulated welding operation and to communicate images correspondingto the virtual weld to the computerized eyewear device.
 20. The weldingsimulator of claim 15, further comprising: a spatial tracker operativelyconnected to the programmable processor-based subsystem; and a mockwelding tool manipulated by the user during the simulated weldingoperation, the mock welding tool is configured to be spatially trackedby the spatial tracker during the simulated welding operation.